Color filter, manufacturing method thereof, and liquid crystal panel with the same

ABSTRACT

The present disclosure provides color filter and a manufacturing method thereof, and a liquid crystal panel with the color filter. The color filter includes a substrate, a black matrix formed on the substrate, a number of spacers integrally formed with the black matrix; and a color filter with a thickness thereof being less than that of the black matrix. Color ink is disposed in the black matrix and is hardened to form the color filter layer. The black matrix and the spacers are integrally formed and made of the black film, which simplifies the manufacturing process of the color filter. Additionally, since the color filter layer is formed by the ink jet printing method, the height of the color filter is unlimited, which allows the black matrix and the spacers to be made of conventional material, and improves the yield rate of the color filter.

BACKGROUND

1. Technical Field

The present disclosure relates to liquid crystal displaying technologiesand, particularly, to a color filter and a manufacturing method thereof,and a liquid crystal panel with the color filter.

2. Description of Related Art

A liquid crystal display (LCD) is a flat panel display (FPD) that usesthe characteristics of liquid crystal to display image. Compared toother types of display, LCD is thin and it requires lower drivingvoltage and lower power consumption, which makes it the mainstreamproduct in the consumer goods market. The liquid crystal panel includesa color filter and a film transistor (TFT) array substrate bonded to thecolor filter. A number of spacers are provided between the color filterand the TFT array substrate for supplying spaces in which the liquidcrystal are filled. The spacers are often disposed on the color filter.

Referring to FIG. 1, generally, the color filter includes a substrate101, a black matrix 102, a color filter layer 103, a common electrode104, and a number of spacers 105. The black matrix 102, the color filterlayer 103, the common electrode 104, and the spacers 105 are alldisposed on the substrate 101. The manufacturing method of the colorfilter often includes the following steps: firstly, coating a black filmon the substrate 101, exposing and developing the black film to form theblack matrix 102 and the spacers 105 integrally formed with the blackmatrix 102; secondly, coating a color resistance film on the substrate101, exposing and developing the color resistance film to form the colorfilter layer 103 in between the black matrix 102; thirdly, forming thecommon electrode 104 on the color filter layer 103. The black matrix 102and the spacers 105 are simultaneously formed in the manufacturingmethod, which simplifies the process of the color filter and reduces thecost thereof.

The thickness of the liquid crystal layer may range from 3 um to 4 umfor ensuring the displaying effect of the liquid crystal display. Thatis, the space between two substrates of the liquid crystal panel,namely, the difference between the total height of the color filter 103and the common electrode 104, and the total height of the black matrix102 and the spacer 105, should reach 3 um to 4 um. Since the colorresistance film forming the color filter layer 103 is coated on theblack matrix 102 and the spacers 105, thus, the black matrix 102 iscovered by the color filter layer 103 and the space between the twosubstrates of the liquid crystal panel is determined by the height ofthe spacer 105. However, because the black film is made of theconventional material, the height of the spacer 105 can only range from0.2 um to 0.6 um by controlling the exposure degree in the exposureprocess of the black film. In this circumstance, in order to increasethe space between the two substrates to meet the requirement, the blackmatrix 102 and the spacers 105 should be made of material of high lightsensitivity. However, the thickness of the black film may be uneven dueto the energy difference between manufacturing machines, which mayincrease the fraction defective of the color filter in the followingmanufacturing process thereof.

SUMMARY

One object of the present disclosure is to a color filter. The colorfilter includes a substrate, a black matrix formed on the substrate, anumber of spacers integrally formed with the black matrix, and a colorfilter formed by an ink jet printing method with a thickness thereofbeing less than that of the black matrix.

Preferably, a number of color resistance regions are defined in theblack matrix for allowing color ink of the color filter to be disposedtherein.

Preferably, each of the spacers includes a first supporting portionformed on an upper surface of the black matrix and a second supportingportion formed on an upper surface of the first supporting portion.

Preferably, the black matrix defines a number of color resistanceregions, and color ink of the color filter is disposed in the colorresistance regions.

Preferably, the color filter engages with an array substrate to form aliquid crystal panel, the black matrix and the spacers are integrallyformed from the black film formed on the substrate, a thickness of theblack film is equal to the sum of the thickness of the color filterlayer and space between the array substrate and the color filter.

Another object of the present disclosure is to provide a manufacturingmethod of a color filter. The method includes the following steps:disposing a black film on a substrate; exposing and developing the blackfilm to form a black matrix and a number of spacers; and disposing colorink into the black matrix by an ink jet printing method, hardening thecolor ink to form a color filter layer with a thickness thereof beingless than a thickness of the black matrix.

Preferably, the step of exposing and developing the black film to form ablack matrix and a number of spacers includes: exposing the black filmwith ultra light rays passing through a mask having gray-tone areas,light transmission areas, and light shielding areas; and developing theexposed black film to form the black matrix and the spacers, defining anumber of color resistance regions in the black matrix.

Preferably, the color ink includes red ink, green ink, and blue ink, andthe step of disposing color ink into the black matrix by an ink jetprinting method includes: disposing the red ink, green ink, and the blueink to the respective color resistance region by the ink jet printingmethod.

Preferably, the step of exposing and developing the black film to form ablack matrix and a number of spacers includes: exposing the black filmwith the ultra light rays passing through the mask having gray-toneareas, light transmission areas, and light shielding areas, each of thegray-tone areas includes two gray scales of different levels; anddeveloping the exposed black film to form the black matrix and thespacers, defining a number of color resistance regions in the blackmatrix, and each of the spacers includes a first supporting portion anda second supporting portion.

Preferably, the color ink includes red ink, green ink, and blue ink, thestep of disposing color ink into the black matrix by an ink jet printingmethod includes: disposing the red ink, the green ink, and the blue inkto the respective color resistance region by the ink jet printingmethod.

Preferably, the color ink includes red ink, green ink, and blue ink, thestep of disposing color ink into the black matrix by an ink jet printingmethod includes: disposing the red ink, green ink, and the blue ink tothe respective color resistance region by the ink jet printing method.

Preferably, the color filter engages with an array substrate to form aliquid crystal panel, the black matrix and the spacers are integrallyformed and made of the black film coated on the substrate, a thicknessof the black film is equal to the sum of the thickness of the colorfilter layer and space between the array substrate and the color filter.

Yet another object of the present disclosure is to provide a liquidcrystal panel. The liquid crystal panel includes an array substrate witha number of pads disposed thereon and a color filter. The color filterincludes a substrate, a black matrix formed on the substrate, a numberof spacers respectively integrally formed with the black matrix andrespectively abutting the pads, and a color filter layer formed by anink jet printing method with a thickness thereof being less than that ofthe black matrix.

Preferably, the black matrix defines a number of color resistanceregions for allowing color ink of the color filter layer to be disposedtherein.

Preferably, the black matrix and the spacers are integrally formed fromthe black film coated on the substrate, and a thickness of the blackfilm is equal to the sum of the thickness of the color filter layer andspace between the array substrate and the color filter.

Preferably, each of the spacers includes a first supporting portionformed on an upper surface of the black matrix and a second supportingportion formed on an upper surface of the corresponding first supportingportion.

Preferably, an opening is formed in each of the pad for clamping thesecond supporting portion of the corresponding spacer therein.

Preferably, the black matrix and the spacers are integrally formed andmade of the black film coated on the substrate, and a thickness of theblack film is equal to the sum of the thickness of the color filterlayer and space between the array substrate and the color filter.

The black matrix of the color filter of the present disclosure isintegrally and simultaneously formed with the spacers, which simplifiesthe manufacturing process of the color filter. Since the color filterlayer of the color filter is formed by the ink jet printing method,which allows the height of the black matrix to be unlimited somehow inthe manufacturing process of the color filter layer. In this way, thedifference between the thickness of the black film coated on thesubstrate and that of the color filter layer can be greater enough tosatisfy the space required between the two substrates of the liquidcrystal panel, and height of the black matrix or height of the spacersdoes not affect the space between the two substrates of the liquidcrystal panel from being influenced by the black matrix and the spacers.Thus, the black matrix and the spacers can be made of conventionalmaterial for improving the yield rate of the color filter.

DESCRIPTION OF THE DRAWINGS

Many aspects of the embodiments can be better understood with referenceto the following drawings. The components in the drawings are notnecessarily dawns to scale, the emphasis instead being placed uponclearly illustrating the principles of the embodiments. Moreover, in thedrawings, like reference numerals designate corresponding partsthroughout the several views.

FIG. 1 is a schematic view of a conventional color filter;

FIG. 2 is a schematic view of a color filter in accordance with a firstembodiment of the present disclosure;

FIG. 3 is a flow chart of a manufacturing method of the color filter ofFIG. 2;

FIG. 4 is a schematic view illustrating an exposure process on a blackfilm by a mask;

FIG. 5 is a schematic view of a black matrix and spacers after adeveloping process of the black film of FIG. 4;

FIG. 6 is a schematic view illustrating the process of disposing colorink to color resistance regions;

FIG. 7 is a schematic view of a liquid crystal panel with the colorfilter of FIG. 2;

FIG. 8 is a schematic view of a color filter in accordance with a secondembodiment of the present disclosure;

FIG. 9 is a schematic view illustrating an exposure process on a blackfilm by a mask;

FIG. 10 is a schematic view of a black matrix and spacers after adeveloping process on the black film;

FIG. 11 is a schematic view of a liquid crystal panel with the colorfilter of FIG. 8.

DETAILED DESCRIPTION

The disclosure is illustrated by way of example and not by way oflimitation in the figures of the accompanying drawings in which likereferences indicate similar elements. It should be noted that referencesto “an” or “one” embodiment is this disclosure are not necessarily tothe same embodiment, and such references mean at least one.

Referring to FIG. 2, a color filter 1, in accordance with a firstembodiment of the present disclosure, is shown. The color filter 1includes a substrate 10, a black matrix 11, a number of spacers 12, anda color filter layer 13. The black matrix 11 is disposed on thesubstrate 10 in the form of matrix. The black matrix 11 defines a numberof color resistance regions. The spacers 12 are integrally formed withthe black matrix 11 and are formed on an upper surface of the blackmatrix 11. The color filter layer 13 is formed by color ink disposed inthe color resistance regions. For example, the color filter layer 13includes a red filter layer, a blue filter layer, and a green filterlayer, which are respectively formed by red ink, blue ink, and greenink. A thickness of the color filter layer 13 is less than that of theblack matrix 11.

Referring to FIG. 3, a manufacturing method of the color filter 1 isprovided. The manufacturing method includes the following steps:

Step S01, coating a black film on a substrate 10.

Step S02, exposing and developing the black film to form the blackmatrix 11 and the spacers 12.

As shown in FIG. 4, the black film is exposed by a mask 20. The mask 20used in the exposure process includes a number of light shielding areas21, a number of light transmission areas 22, and a number of gray-toneareas 23. Ultra light rays irradiate on the black film after passingthrough the mask 20. Since energies of the ultra light rays irradiatingon the black film after passing through the mask 20 are different fromeach other, the thicknesses of different parts of the black film aredifferent from each other after being developed. As shown in FIG. 5,after the exposure process and the developing process, the parts of theblack film which are located under the light shielding areas 21respectively are removed completely; the parts of the black film whichare located under the light transmission areas 22 respectively are keptoriginal, and the parts of the black film which are located under thegray-tone areas 23 respectively are partly removed. Thus, the blackmatrix 11 and the spacers 12 are formed. The black matrix 11 defines anumber of the color resistance regions therein.

Step S03: forming the color filter layer 13.

Referring to FIG. 6, the color ink is disposed into the color resistanceregions. The red ink, blue ink, and green ink are disposed into thecorresponding color resistance region via an ink jet printing method.Each color resistance region is filled in the ink of the same color. Theink then is hardened to form the red filter layer, a blue filter layer,and a green filter layer, which form the color filter layer 13, as shownin FIG. 2. The thickness of the color filter layer 13 is less than thatof the black matrix 11.

The black matrix 11 and the spacers 12 of the color filter 1 of thepresent disclosure are integrally and simultaneously formed, whichsimplifies the manufacturing process of the color filter 1. Since thecolor filter layer 13 of the color filter 1 is formed by the ink jetprinting method, which allows the height of the black matrix 11 to beunlimited somehow in the manufacturing process of the color filter layer13. In this way, the difference between the thickness of the black filmcoated on the substrate 10 and that of the color filter layer 13 can begreater enough to satisfy the space required between the two substratesof the liquid crystal panel, and height of the black matrix 11 or heightof the spacers 12 does not affect the space between the two substratesof the liquid crystal panel. Thus, the black matrix 11 and the spacers12 can be made of conventional material for improving the yield rate ofthe color filter 1.

Referring to FIG. 7, a liquid crystal panel with the color filter 1, isshown. The liquid crystal panel includes the above color filter 1 and anarray substrate 2. A number of pads 14 are disposed on the arraysubstrate 2 for respectively abutting the spacers 12 of the color filter1. With the pads 14, the relative movement between the spacers 12 andthe array substrate 2 can be limited.

Referring to FIG. 8, a color filter, in accordance with a secondembodiment, is shown. The difference between the color filter of thesecond embodiment and the color filter of the first embodiment lies inthat, in this embodiment, each of the spacer 12 is step-profiled, andincludes a first supporting portion 121 and a second supporting portion122.

Referring to FIGS. 9 and 10, in which FIG. 9 is a schematic viewillustrating an exposure process on a black film by a mask, and FIG. 10is a schematic view of a black matrix and spacers after a developingprocess on the black film. The difference between the manufacturingmethod of the embodiment and that of the first embodiment lies in that,each of the gray-tone areas of the mask used in the exposure anddeveloping process on the black film includes two gray scales 231, 232of different levels. The black film is exposed and developed to form theblack matrix 11 and the step-profiled spacers 12. As shown in FIG. 10,each of the spacers 12 includes a first supporting portion 121 and asecond supporting portion 122.

The black matrix 11 of the color filter 1 of the present disclosure isintegrally and simultaneously formed with the spacers 12, whichsimplifies the manufacturing process of the color filter 1. Since thecolor filter layer 13 of the color filter 1 is formed by the ink jetprinting method, which allows the height of the black matrix 11 to beunlimited somehow in the manufacturing process of the color filter layer13. In this way, the difference between the thickness of the black filmcoated on the substrate 10 and that of the color filter layer 13 can begreater enough to satisfy the space required between the two substratesof the liquid crystal panel, and height of the black matrix 11 or heightof the spacers 12 does not affect the space between the two substratesof the liquid crystal panel. Thus, the black matrix 11 and the spacers12 can be made of conventional material for improving the yield rate ofthe color filter 1.

Referring to FIG. 11, a liquid crystal panel with the color filter ofthe second embodiment is shown. The liquid crystal panel is providedwith a number of pads 15 disposed on the array substrate 2. An openingis defined in the middle portion of each of the pads 15. When thespacers 12 of the color filter 1 respectively abut the pads 15, thesecond supporting portion 122 is received in the opening of thecorresponding pad 15 for limiting the relative movement between thespacers 12 and the array substrate 2.

Even though information and the advantages of the present embodimentshave been set forth in the foregoing description, together with detailsof the mechanisms and functions of the present embodiments, thedisclosure is illustrative only; and that changes may be made in detail,especially in matters of shape, size, and arrangement of parts withinthe principles of the present embodiments to the full extend indicatedby the broad general meaning of the terms in which the appended claimsare expressed.

What is claimed is:
 1. A color filter, comprising: a substrate; a blackmatrix formed on the substrate; a plurality of spacers integrally formedwith the black matrix; and a color filter formed by an ink jet printingmethod with a thickness thereof being less than that of the blackmatrix.
 2. The color filter as claimed in claim 1, wherein a pluralityof color resistance regions are defined in the black matrix for allowingcolor ink of the color filter to be disposed therein.
 3. The colorfilter as claimed in claim 1, wherein each of the spacers comprises afirst supporting portion formed on an upper surface of the black matrixand a second supporting portion formed on an upper surface of the firstsupporting portion.
 4. The color filter as claimed in claim 3, whereinthe black matrix defines a plurality of color resistance regions, andcolor ink of the color filter is disposed in the color resistanceregions.
 5. The color filter as claimed in claim 1, wherein the colorfilter engages with an array substrate to form a liquid crystal panel,the black matrix and the spacers are integrally formed from the blackfilm formed on the substrate, a thickness of the black film is equal tothe sum of the thickness of the color filter layer and space between thearray substrate and the color filter.
 6. A manufacturing method of acolor filter, comprising: disposing a black film on a substrate;exposing and developing the black film to form a black matrix and aplurality of spacers; and disposing color ink into the black matrix byan ink jet printing method, hardening the color ink to form a colorfilter layer with a thickness thereof being less than a thickness of theblack matrix.
 7. The manufacturing method as claimed in claim 6, whereinthe step of exposing and developing the black film to form a blackmatrix and a plurality of spacers comprises: exposing the black filmwith ultra light rays passing through a mask having gray-tone areas,light transmission areas, and light shielding areas; and developing theexposed black film to form the black matrix and the spacers, defining aplurality of color resistance regions in the black matrix.
 8. Themanufacturing method as claimed in claim 7, wherein the color inkcomprising red ink, green ink, and blue ink, and the step of disposingcolor ink into the black matrix by an ink jet printing method comprises:disposing the red ink, green ink, and the blue ink to the respectivecolor resistance region by the ink jet printing method.
 9. Themanufacturing method as claimed in claim 6, wherein the step of exposingand developing the black film to form a black matrix and a plurality ofspacers comprises: exposing the black film with the ultra light rayspassing through the mask having gray-tone areas, light transmissionareas, and light shielding areas, each of the gray-tone areas comprisestwo gray scales of different levels; and developing the exposed blackfilm to form the black matrix and the spacers, defining a plurality ofcolor resistance regions in the black matrix, and each of the spacerscomprises a first supporting portion and a second supporting portion.10. The manufacturing method as claimed in claim 9, wherein the colorink comprises red ink, green ink, and blue ink, the step of disposingcolor ink into the black matrix by an ink jet printing method comprises:disposing the red ink, the green ink, and the blue ink to the respectivecolor resistance region by the ink jet printing method.
 11. Themanufacturing method as claimed in claim 6, wherein the color inkcomprises red ink, green ink, and blue ink, the step of disposing colorink into the black matrix by an ink jet printing method comprises:disposing the red ink, green ink, and the blue ink to the respectivecolor resistance region by the ink jet printing method.
 12. Themanufacturing method as claimed in claim 6, wherein the color filterengages with an array substrate to form a liquid crystal panel, theblack matrix and the spacers are integrally formed and made of the blackfilm coated on the substrate, a thickness of the black film is equal tothe sum of the thickness of the color filter layer and space between thearray substrate and the color filter.
 13. A liquid crystal panel,comprising: an array substrate with a plurality of pads disposedthereon; and a color filter, comprising: a substrate; a black matrixformed on the substrate; a plurality of spacers respectively integrallyformed with the black matrix and respectively abutting the pads; and acolor filter layer formed by an ink jet printing method with a thicknessthereof being less than that of the black matrix.
 14. The liquid crystalpanel as claimed in claim 13, wherein the black matrix defines aplurality of color resistance regions for allowing color ink of thecolor filter layer to be disposed therein.
 15. The liquid crystal panelas claimed in claim 13, wherein the black matrix and the spacers areintegrally formed from the black film coated on the substrate, and athickness of the black film is equal to the sum of the thickness of thecolor filter layer and space between the array substrate and the colorfilter.
 16. The liquid crystal panel as claimed in claim 13, whereineach of the spacers comprises a first supporting portion formed on anupper surface of the black matrix and a second supporting portion formedon an upper surface of the corresponding first supporting portion. 17.The liquid crystal panel as claimed in claim 16, wherein an opening isformed in each of the pad for clamping the second supporting portion ofthe corresponding spacer therein.
 18. The liquid crystal panel asclaimed in claim 17, wherein the black matrix and the spacers areintegrally formed and made of the black film coated on the substrate,and a thickness of the black film is equal to the sum of the thicknessof the color filter layer and space between the array substrate and thecolor filter.